Prodigy Generation II Manual Powder Spray Gunemanuals.nordson.com/finishing/files/Powder/1077434.pdf · Prodigy Generation II Manual Powder Spray Gun 3 2019 Nordson Corporation Part

Prodigy� Generation II Manual Powder Spray Gun

Customer Product ManualPart 1077434-12

Issued 6/19

NORDSON CORPORATION • AMHERST, OHIO • USA

This document is subject to change without notice.Check http://emanuals.nordson.com for the latest version.

For parts and technical support, call the Industrial Coating Systems Customer Support Center at (800) 433-9319

Part 1077434-12 � 2019 Nordson Corporation

Table of Contents

Safety 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Qualified Personnel 1. . . . . . . . . . . . . . . . . . . . . . . . .Intended Use 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Regulations and Approvals 1. . . . . . . . . . . . . . . . . .Personal Safety 1. . . . . . . . . . . . . . . . . . . . . . . . . . . .Fire Safety 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Grounding 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Aggressive Substances 2. . . . . . . . . . . . . . . . . . . . .Action in the Event of a Malfunction 3. . . . . . . . . . .Disposal 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Description 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Features 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Specifications 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Air Quality Requirements 5. . . . . . . . . . . . . . . . . . . .Equipment Rating 5. . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cable and Pattern Air Tubing 5. . . . . . . . . . . . . . . .Determining Powder Tubing Lengths 6. . . . . . . . . .Coiling the Powder Tubing 6. . . . . . . . . . . . . . . . . . .Tubing Installation 7. . . . . . . . . . . . . . . . . . . . . . . . . .

Gun Connection 7. . . . . . . . . . . . . . . . . . . . . . . . .Pump Connection 7. . . . . . . . . . . . . . . . . . . . . . .

ATEX Special Condition For Safe Use: 8. . . . . . . . .Operation 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Presets 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Gun ON LED 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pattern Control Trigger 8. . . . . . . . . . . . . . . . . . . . . .

Maintenance 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Nozzle Disassembly and Cleaning 9. . . . . . . . . . . .

Troubleshooting 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Continuity and Resistance Tests 12. . . . . . . . . . . . . .

Multiplier and Resistor AssemblyResistance Test 12. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Resistance Test − Control Cable End to Adapter Spring Plunger 12. . . . . . . . . . . . . . . . . . .Resistance Test Using the OptionalShorting Plug 13. . . . . . . . . . . . . . . . . . . . . . . . . . .Resistor Resistance Test 13. . . . . . . . . . . . . . . . .

Control Cable Continuity Tests 14. . . . . . . . . . . . . . .Trigger Switch Continuity Test 14. . . . . . . . . . . . . . . .

Repair 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Nozzle and Powder Tubing Replacement 15. . . . . .Control Cable Replacement 15. . . . . . . . . . . . . . . . .Resistor Replacement 17. . . . . . . . . . . . . . . . . . . . . .

Resistor Removal 17. . . . . . . . . . . . . . . . . . . . . . . .Resistor Installation 17. . . . . . . . . . . . . . . . . . . . . .

Multiplier Replacement 18. . . . . . . . . . . . . . . . . . . . . .Removal 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Assembly 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parts 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Prodigy Generation II Manual Spray Gun 19. . . . . .Service Kits 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Options 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Powder and Air Tubing 21. . . . . . . . . . . . . . . . . . . . . .Conical Nozzles 22. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Conical Nozzle Components 22. . . . . . . . . . . . . .Flat Spray, Cross, and Pinpoint Nozzles 23. . . . . . .

Flat Spray, Cross, andPinpoint Nozzle Components 24. . . . . . . . . . . . . .

Contact UsNordson Corporation welcomes requests for information, comments, andinquiries about its products. General information about Nordson can befound on the Internet using the following address:http://www.nordson.com.Address all correspondence to:

Nordson CorporationAttn: Customer Service555 Jackson StreetAmherst, OH 44001

NoticeThis is a Nordson Corporation publication which is protected by copyright.Original copyright date 2004. No part of this document may bephotocopied, reproduced, or translated to another language without theprior written consent of Nordson Corporation. The information containedin this publication is subject to change without notice.

Trademarks

Prodigy, HDLV, Nordson, and the Nordson logo are registered trademarksof Nordson Corporation.

All other trademarks are the property of their respective owners.

Change Record i

Part 1077434-12� 2019 Nordson Corporation

Change RecordRevision Date Change

A04 9/09 Changed part number of tubing adapter item 7 from 1077263 to1093440.

A05 7/10 Updated pattern air specification.

06 6/12 Updated approvals label, added serial number information tospecifications, updated CE Declaration of Conformity.

07 11/12 Changed approvals label, updated CE Declaration of ConformityDOC14030A02.

08 2/13 Updated part numbers for lance extensions under Options.

09 6/15 Clear powder tubing option added.

10 8/18 Added repair kit

11 11/18 Replacing part number 1606690 with 1615026

12 6/19 Page 22: Update powder air tubing part numbers/descriptions

Change Recordii


Prodigy� Generation II Manual Powder Spray Gun 1


Prodigy� Generation II Manual Powder Spray Gun

Safety

Read and follow these safety instructions. Task-and equipment-specific warnings, cautions, andinstructions are included in equipmentdocumentation where appropriate.

Make sure all equipment documentation, includingthese instructions, is accessible to all personsoperating or servicing equipment.

Qualified Personnel Equipment owners are responsible for making surethat Nordson equipment is installed, operated, andserviced by qualified personnel. Qualifiedpersonnel are those employees or contractors whoare trained to safely perform their assigned tasks.They are familiar with all relevant safety rules andregulations and are physically capable ofperforming their assigned tasks.

Intended Use Use of Nordson equipment in ways other thanthose described in the documentation supplied withthe equipment may result in injury to persons ordamage to property.

Some examples of unintended use of equipmentinclude

� using incompatible materials

� making unauthorized modifications

� removing or bypassing safety guards orinterlocks

� using incompatible or damaged parts

� using unapproved auxiliary equipment

� operating equipment in excess of maximumratings

Regulations and Approvals Make sure all equipment is rated and approved forthe environment in which it is used. Any approvalsobtained for Nordson equipment will be voided ifinstructions for installation, operation, and serviceare not followed.

All phases of equipment installation must complywith all federal, state, and local codes.

Personal Safety To prevent injury follow these instructions.

� Do not operate or service equipment unless youare qualified.

� Do not operate equipment unless safetyguards, doors, or covers are intact andautomatic interlocks are operating properly. Donot bypass or disarm any safety devices.

� Keep clear of moving equipment. Beforeadjusting or servicing any moving equipment,shut off the power supply and wait until theequipment comes to a complete stop. Lock outpower and secure the equipment to preventunexpected movement.

� Relieve (bleed off) hydraulic and pneumaticpressure before adjusting or servicingpressurized systems or components.Disconnect, lock out, and tag switches beforeservicing electrical equipment.

� To prevent injury, be aware of less-obviousdangers in the workplace that often cannot becompletely eliminated, such as hot surfaces,sharp edges, energized electrical circuits, andmoving parts that cannot be enclosed orotherwise guarded for practical reasons.

� Obtain and read Safety Data Sheets (SDS) forall materials used. Follow the manufacturer’sinstructions for safe handling and use ofmaterials, and use recommended personalprotection devices.

Prodigy� Generation II Manual Powder Spray Gun2


Fire Safety To avoid a fire or explosion, follow theseinstructions.

� Do not smoke, weld, grind, or use open flameswhere flammable materials are being used orstored.

� Provide adequate ventilation to preventdangerous concentrations of volatile materialsor vapors. Refer to local codes or your materialSDS for guidance.

� Do not disconnect live electrical circuits whileworking with flammable materials. Shut offpower at a disconnect switch first to preventsparking.

� Know where emergency stop buttons, shutoffvalves, and fire extinguishers are located. If afire starts in a spray booth, immediately shut offthe spray system and exhaust fans.

� Clean, maintain, test, and repair equipmentaccording to the instructions in your equipmentdocumentation.

� Use only replacement parts that are designedfor use with original equipment. Contact yourNordson representative for parts informationand advice.

Grounding

WARNING: Operating faulty electrostaticequipment is hazardous and can causeelectrocution, fire, or explosion. Makeresistance checks part of your periodicmaintenance program. If you receive evena slight electrical shock or notice staticsparking or arcing, shut down all electricalor electrostatic equipment immediately. Donot restart the equipment until the problemhas been identified and corrected.

Grounding inside and around the booth openingsmust comply with NFPA requirements for Class II,Division 1 or 2 Hazardous Locations. Refer toNFPA 33, NFPA 70 (NEC articles 500, 502, and516), and NFPA 77, latest conditions.

� All electrically conductive objects in the sprayareas shall be electrically connected to groundwith a resistance of not more than 1 megohmas measured with an instrument that applies atleast 500 volts to the circuit being evaluated.

� Equipment to be grounded includes, but is notlimited to, the floor of the spray area, operatorplatforms, hoppers, photoeye supports, andblow-off nozzles. Personnel working in thespray area must be grounded.

� There is a possible ignition potential from thecharged human body. Personnel standing on apainted surface, such as an operator platform,or wearing non-conductive shoes, are notgrounded. Personnel must wear shoes withconductive soles or use a ground strap tomaintain a connection to ground when workingwith or around electrostatic equipment.

� Operators must maintain skin-to-handle contactbetween their hand and the gun handle toprevent shocks while operating manualelectrostatic spray guns. If gloves must beworn, cut away the palm or fingers, wearelectrically conductive gloves, or wear agrounding strap connected to the gun handle orother true earth ground.

� Shut off electrostatic power supplies andground gun electrodes before makingadjustments or cleaning powder spray guns.

� Connect all disconnected equipment, groundcables, and wires after servicing equipment.

Aggressive Substances

If the equipment is likely to come into contact withaggressive substances, then it is the responsibilityof the user to take suitable precautions that preventit from being adversely affected, thus ensuring thatthe type of protection provided by the equipment isnot compromised.

Aggressive substances: e.g. acidic liquids orgases that may attack metals, or solvents that mayaffect polymeric materials.

Suitable precautions: regular check as part ofroutine inspections or establishing from thematerial’s data sheets that it is resistant to specificchemicals.

Please contact Nordson Corporation if you areconcerned or unsure about the suitability of theproduct with relation to coming into contact withparticularly aggressive substances.



Action in the Event of aMalfunction If a system or any equipment in a systemmalfunctions, shut off the system immediately andperform the following steps:

� Disconnect and lock out electrical power. Closepneumatic shutoff valves and relieve pressures.

� Identify the reason for the malfunction andcorrect it before restarting the equipment.

Disposal Dispose of equipment and materials used inoperation and servicing according to local codes.

Description The Prodigy Manual Powder Spray Gun usesspecially designed conical and flat-spray nozzles toatomize, shape, and spray dense-phase powderdelivered by Nordson HDLV� (high-density powder,low-velocity air) pumps.

Features � 8-mm flexible tubing used for powder delivery

� Separate high voltage and powder paths.

� Special pattern control trigger toggles betweenuser-programmable high and low pattern airand powder flows.

� Shipped with a 70� conical nozzle and adual-slot flat-spray nozzle. Optional conical, flatspray, cross, and pinpoint nozzles are available.

� User-friendly controller with LCD display.

� Up to 10 user-programmable coating recipes.

1

2

3

4

5

6

78

9

Figure 1 Prodigy Manual Powder Spray Gun

1. Gun body2. Adapter3. Conical nozzle

4. Nozzle electrode5. Pattern control trigger6. Trigger

7. Flexible powder tubing(8 mm)

8. Control cable9. Pattern air fitting (6 mm)

Note: Powder and pattern air tubing are not shipped with the spray gun. Tubing is included in manual gun systems.



Description (contd)

19

67

9

14

18

17

11

1615

12 13

2010

123

45

8

SIRA05ATEX5212X EEx 2mJ

1180 II 2D

1713

NORDSON CORPORATION

Prodigy�

Figure 2 Spray Gun Section View

1. Nozzle electrode*2. Nozzle electrode ring*3. Tubing adapter4. Adapter5. Resistor6. Resistor holder7. Contact spacer

8. Voltage multiplier9. Ground stud

10. Cable/multiplier connection11. 6-mm tube fitting (pattern air)12. Control cable13. 8-mm flexible powder tubing14. Switch keypad

15. Spray trigger16. Pattern control trigger17. Lock knob18. Retainer nut19. Nozzle insert*20. Nozzle*

Note: Parts marked with an asterisk (*) are part of the nozzle assembly. Powder and pattern air tubing are included withmanual gun systems only.



Specifications Specifications are subject to change without notice.

Electrical Output

Maximum rated output voltage at the electrode: 95 kV ± 10%

Maximum rated output current at the electrode: 100 μA ± 10%

Air Pressure and Flow Requirements

Minimum input air: 4 bar (60 psi)

Maximum input air: 6.9 bar (100 psi)

Pattern air: 5.9 bar (85 psi), 6−57 l/min. (0.2−4.0 scfm)

Temperature Requirements

Maximum ambient temperature 40 �C (104 �F)

Air Quality Requirements Powder spray systems require clean, dry, oil-freecompressed air. Moist or oil-contaminated air cancause the powder to clog in the pump, powder feedtubing, or spray gun.

Use 3-micron filter/separators with automatic drainsand a refrigerated or regenerative desiccant-typeair dryer that can produce a 3.4 �C (38 �F) or lowerdewpoint at 6.9 bar (100 psi).

Equipment Rating This applicator is rated for use in a potentiallyexplosive environment: Class II, Division I, GroupF & G, Zone 21 or Zone 22.

Serial Number Interpretation The gun serial number contains the location, year,and month it was manufactured. The serialnumber starts with “AA12A”. The “AA” means theproduct was built in Amherst, Ohio; the “12”meaning the year 2012. The “A” means the monthof January, “B” would be February, and so on.

Installation WARNING: Allow only qualified personnelto perform the following tasks. Follow thesafety instructions in this document and allother related documentation.

WARNING: Installation in Europe shallcarried out by suitably trained personnel inaccordance with the applicable code ofpractice. EN60079-14

Cable and Pattern Air Tubing See Figure 2.

1. Connect the control cable (12) to the guncontroller receptacle labeled GUN and tightenthe cable nut securely.

NOTE: Refer to page 21 for optional 4 and6-meter extension cables. Do not use morethan two extension cables.

NOTE: Powder and pattern air tubing are suppliedwith manual gun systems or can be orderedseparately. Refer to page 22 for tubing partnumbers.

2. Connect blue 6-mm pattern air tubing from theappropriate pattern air outlet fitting on the pumpcontrol cabinet to the tube fitting (11) on the gunhandle.



Determining Powder TubingLengths To achieve maximum powder flow, the end-to-endlength of the suction and delivery tubing must bewithin the ranges shown.

� Keep the suction tubing as short as possiblewithin the limits shown.

� Keep the delivery tubing as close to 20 m(65.5 ft) as possible. Using shorter lengthsincreases the possibility of surging.

� Route the powder tubing on the floor, especiallyif the delivery tubing must be longer than 20 m(65.55 ft). The pump will still deliver powderthrough longer lengths of tubing, but at areduced flow rate.

Suction Tubing:1−3 m (3.5−12 ft)

end-to-end

Delivery Tubing:9−23 m (30−75 ft)

end-to-endRecommended Length:

20 m (65.5 ft)

Figure 3 Determining Powder Tubing Length

Coiling the Powder Tubing Your Prodigy system will deliver consistent powderflow if the powder tubing is coiled using theseguidelines:

� Keep the loops in the coil at least 1 m (3.25 ft)in diameter.

� Have as few loops as possible in the coil.

� Lay the coil flat on the floor. Do not hang thecoil vertically or powder will settle at the bottomof the coil when the gun is triggered off andsurge when the gun is triggered on again.

GOOD

BAD

3 ft

Figure 4 Coiling the Powder Tubing



Tubing Installation NOTE: Use a tubing cutter to cut the 8-mm powderdelivery and suction tubing to the desired lengths.The ends must be square. Refer to page 22 for anoptional tubing cutter.

Gun Connection

See Figure 2. Use this procedure to install flexiblepowder tubing.

1. Remove the nozzle and tubing adapter.

2. Thread the lock knob (17) into the gun bodyand tighten.

3. Push the tube insertion tool (a length of meshsleeving) through the lock knob and out thefront of the gun until you can grasp the end.Refer to the spray gun parts list for the tool partnumber.

4. Insert the end of the flexible tubing into theknob end of the mesh sleeving, then pull on thegun end of the sleeving, until you pull the tubingthrough the knob and out the end of the gun.

5. Install the tubing adapter (3) into the end of theflexible tubing.

6. Gently pull the tubing back through the lockknob until the tubing adapter is up against theflange molded in the end of the gun body.

NOTE: The tubing adapter has two notches180� apart to fit around the molded electrode inthe spray gun.

7. Install the nozzle (20) on the spray gun.

Pump Connection

1. Route the delivery tubing to the appropriatepowder pump, coiling it as shown on page 6.

1. See Figure 5. Remove the rear (outlet)retaining nut (1) and O-ring (2) from the pump.

2. Install the O-ring (3) onto the tubing adapter (3),until it is up against the adapter flange.

3. Install the end of the adapter into the pump.

4. Install the retaining nut over the end of thebarbed adapter, thread the nut onto the wearblock, and tighten it finger-tight.

5. Push the flexible powder tubing (4) over thebarbed end of the adapter.

6. Connect the suction tubing as described in thepump manual or the Color-on-Demandinstallation manual.

7. Use cable ties to bundle together the guncontrol cable, pattern air tubing, and powdertubing.

1

2

4

3

Figure 5 Flexible Tubing Connection to Pump

1. Tube retaining nut2. O-ring

3. Barbed tubing adapter4. Flexible tubing



ATEX Special ConditionFor Safe Use This applicator shall only be used with the ProdigyManual Controller.

Operation

WARNING: This equipment can bedangerous unless it is used in accordancewith the rules laid down in this manual.

All gun functions are set and controlled by themanual gun controller.

Presets A preset is a group of spray settings. The guncontroller provides 10 presets. Use the presets tosave optimal spray settings for parts with differentfeatures.

Gun ON LED The LED on the end plate lights when the spraytrigger is pulled and high voltage is generated.

Pattern Control Trigger The pattern control trigger toggles between thepreset settings (High mode) and the Low modesettings. Use it to change the pattern air andpowder flow as needed when part features change.When in Low mode, a down-pointing arrow (⇓) isappears to the right of the gun icon.

NOTE: If you change presets while spraying inLow mode, the controller immediately switches toHigh mode, spraying with the new preset settings.

Maintenance WARNING: Inspection and maintenanceof this equipment in Europe shall carriedout by suitably trained personnel inaccordance with the applicable code ofpractice. EN60079-17

Daily: Blow off the gun exterior with low-pressurecompressed air and wipe it clean with a soft cloth.

Weekly: Manually perform a hard purge, thenremove the retaining nut, nozzle, and tubingadapter. Inspect the tubing adapter and nozzle forwear. Replace any worn parts.

Inspect the barbed tubing adapter(s) at the pumpand/or hopper for wear and replace if necessary.

Periodically: Check the resistance of the voltagemultiplier and resistor with a megohm meter asdescribed in Continuity and Resistance Checks onpage 12. Replace any components that do notmeet the specifications.

As Required: Disassemble the nozzle and cleanthe internal parts. Replace any worn parts. Referto Nozzle Disassembly and Cleaning on thefollowing page for instructions.



Nozzle Disassembly and Cleaning

Requirements: Nozzle Tool 1073682

1. Hold the nozzle firmly in one hand. Thread thetool onto the threaded end of the insert until itbottoms out on the electrode ring.

InsertElectrode RingTool

Figure 6 Nozzle Disassembly Step 1 (Shown with NutInstalled)

2. Turn the tool clockwise while pulling on it untilthe electrode ring/insert assembly comes out ofthe nozzle.

NOTE: If the electrode is pulled out of the nozzleshell, be careful to not lose it. The dual slot nozzlehas the electrode glued in.

Figure 7 Nozzle Disassembly Step 2A

Electrode Ring/Insert Assembly

Figure 8 Nozzle Disassembly Step 2B (New StyleAssembly Shown)

3. Unscrew the tool from the electrode ring/insertassembly and blow off the assembly withcompressed air.

Figure 9 Nozzle Disassembly Step 3 (New StyleShown)

4. To remove any impact fusion, place the nozzleand nozzle nut in an ultrasonic cleaner. Use 1/2cup of liquid Mr. Clean or equivalent per gallonof water as a cleaning solution. Rinse and blowoff with compressed air. If desired, remove thenozzle nut from the nozzle by sliding the nutforward then turning it clockwise to unscrew it.

NOTE: See Figure 11. Old style nozzles have adisk-shaped filter (3) installed on the outside of theinsert (6) and held on by the electrode ring (2).New style nozzles have a conical filter that isinstalled inside the front end of the insert. The oldstyle filter and insert are obsolete. if you arereplacing the filter on an old style nozzle, you mustalso order a new insert. The new filters areavailable in quantities of 10.



Nozzle Disassembly and Cleaning (contd)

5. Blow off the insert and filter. If the filter isclogged with powder, remove it and replace itwith a new one. When removing the new stylefilter from the insert, be careful not to scratchthe inside surface of the insert.

See Figure 10 to re-assemble the nozzle.

1. Make sure the electrode ring is threaded all theway onto the insert.

2. Thread the tool onto the threaded end of theinsert.

3. Turn the tool counterclockwise to remove itfrom the insert. Check the nozzle. Theelectrode ring should be approximately 1/4 inchinside the nozzle lip.

Electrode Ring

Nozzle Lip

Figure 10 Nozzle Re-assembly

76

54

32

1

OLD STYLE NOZZLE COMPONENTS

12

3

4 5

7

6

NEW STYLE NOZZLE COMPONENTS

8

8

Figure 11 Internal Components of Nozzle Assemblies

1. O-ring2. Electrode ring3. Filter

4. O-ring5. O-ring6. Insert

7. Electrode8. Nozzle shell

Note: All internal components, except the electrodes, are the same for all nozzles. For flat-spray, cross, and pinpointnozzles, the electrode is glued into the nozzle shell with epoxy and cannot be replaced separately.



Troubleshooting WARNING: Allow only qualified personnelto perform the following tasks. Follow thesafety instructions in this document and allother related documentation.

These procedures cover only the most commonproblems that you may encounter. If you cannotsolve the problem with the information given here,contact your local Nordson representative for help.

Problem Possible Cause Corrective Action

1. Unsteady orinadequate powderflow

Problem with powder pump Refer to pump manual fortroubleshooting.

Blockage in powder tubing Perform a hard purge to clear tubing.Replace tubing if partially orcompletely blocked.

Plugged nozzle Remove nozzle and clean.

2. Uneven pattern Insufficient pattern air flow Increase pattern air flow.

Worn powder tube Remove powder tube from gun andcheck for worn passageway.

3. Loss of wrap, poortransfer efficiency

Low electrostatic voltage Increase the electrostatic voltage (kVor μA setting).

Poorly grounded parts Check the conveyor chain, rollers,and part hangers for powder buildup.The resistance between the partsand ground must be 1 megohm orless. For best results, 500 ohms orless is recommended.

Poor connection in high voltagepath inside spray gun

Perform the Multiplier and ResistorAssembly Resistance Tests onpage 12.

Fault in controller Refer to Troubleshooting in the guncontroller manual.

4. No kV output from thespray gun (LED onthe spray gun doesnot light)

Damaged control cable Perform the control cable continuitytests on page 14.

If an open or short is found, replacethe cable.

Fault in controller Refer to Troubleshooting in the guncontroller manual.

5. No kV output from thespray gun (LED onthe spray gun lights)

Faulty voltage multiplier or poorconnection in high voltage pathinside spray gun

Perform the resistance tests onpage 12.

Check all high voltage pathconnections.

6. No kV output and nopowder output

Faulty trigger switch or controlcable

Perform the control cable continuitytests on page 14, and the triggerswitch test on page 14.

Faulty controller wiring harness Check the wiring between the GUNreceptacle and the circuit board.

Faulty controller circuit board Check the circuit board as describedin the controller manual.



Continuity and ResistanceTests

WARNING: Turn off the electrostaticvoltage and ground the spray gunelectrode before performing the followingtasks. Failure to observe this warningcould result in a severe shock.

Use the following tests to isolate problems with thevoltage multiplier or resistor, control cable, andtrigger switch.

Multiplier and Resistor AssemblyResistance Test

Resistance tests must be made with a 500 voltmegohm meter.

CAUTION: Short together the three pins inthe multiplier receptacle, or the designatedpins in the control cable, before testing thecontinuity and resistance of themultiplier/resistor/electrode assembly. Ifnot shorted, the multiplier could bedamaged.

Use the optional shorting plug shown in Figure 13when testing resistance from the multiplierreceptacle to the adapter spring plunger. Refer toOptions in Parts for the shorting plug part number.

Resistance Test − Control Cable Endto Adapter Spring Plunger 1. See Figure 12. Remove the nozzle.

2. Disconnect the control cable from the manualcontrol unit.

3. Short together cable connector pins J1−2, J1−3,and J1−4 and connect them to the positivemegohm meter probe.

4. Connect the negative megohm meter probe tothe adapter spring plunger.

The megohm meter reading should be350−420 megohms. If the reading is out of thisrange, test the resistor separately. If the resistorpasses the test, replace the multiplier.

Pin 2

Pin 3

Pin 4

350−420megohms

Figure 12 Cable End to Spring Plunger Test



Resistance Test Using theOptional Shorting Plug 1. See Figure 13. Remove the end cap and

nozzle from the spray gun.

2. Disconnect the multiplier connector from themultiplier receptacle.

3. Connect the shorting plug connector to themultiplier receptacle.

4. Connect the megohm meter positive probe tothe shorting plug ring-tong terminal and thenegative probe to the spring plunger. (If thereading is infinite, switch the probes).

5. The megohm meter should read350−420 megohms. If the reading is out of thisrange, test the resistor separately. If theresistor passes the test, replace the multiplier.

Shorting Plug

350−420megohms

Red

Black

Figure 13 Test with Shorting Plug

Resistor Resistance Test 1. Remove the resistor/electrode assembly as

described in Resistor and ElectrodeReplacement on page 17.

2. See Figure 14. Connect the megohm meterprobes to the resistor spring and electrodespring.

The megohm meter reading should be153−187 megohms. If it is out of this range,replace the resistor. If it is within this range, but themultiplier/resistor resistance check was out ofrange, replace the multiplier.

153−187megohms

Red Black

Figure 14 Resistor Resistance Test



Control Cable Continuity Tests Make continuity tests with a standard ohmmeter.Use the following table and Figure 15.

NOTE: The first two tests in the following table canbe made by disconnecting the cable from themanual control unit. All other tests requiredisconnecting the J2, J3, and ground connectorsfrom the gun as described in Control CableReplacement on page 15.

Test for continuity between:

J1 pins 1 and 2, spray trigger pressed

J1 pins 2 and 5, pattern air trigger pressed

J1 pin 1 and J3 pin 1

J1 pin 2 and J2 pin 3 and J3 pin 2




J1 pin 6 and ground terminal

J3

J2

J1

12

3

456

1

2

34 2

13J1 J2J3

Ground

(N/C)

J1−1

J1−2J1−3J1−4J1−5J1−6

J3−4J3−3J3−2J3−1

J2−1

J2−3J2−2

SPRAY TRIGGER +

COMMON

+VDC

uA FEEDBACK

PATTERN TRIGGER +

GND

SHIELD

CABLE GND

IC WIRE

MOLDED INTOSTRAIN RELIEF

+VDC

uA FEEDBACK

COMMON

SPRAY TRIGGER +

COMMON

PATTERN TRIGGER +

org

wht

blu

Figure 15 Control Cable Continuity Tests

Trigger Switch Continuity Test Disconnect the control cable from the triggerswitch, as described in Cable Replacement onpage 15.

Test for continuity using the following table andFigure 16.

Pins Trigger Results

1 and 2Off (Open) No continuity

On (Closed) Continuity

2 and 3Off (Open) No continuity

On (Closed) Continuity

Pin

21

43

J3

1 Spray Trigger2 Common3 Pattern Control Trigger4 N/C

Function

Figure 16 Trigger Switch Continuity Test



Repair WARNING: Allow only qualified personnelto perform the following tasks. Follow thesafety instructions in this document and allother related documentation.

WARNING: Turn off the electrostaticvoltage and ground the spray gunelectrode before performing the followingtasks. Failure to observe this warningcould result in a severe shock.

Nozzle and Powder TubingReplacement

78

9

Figure 17 Remove the Nozzle and Tubing Adapter

1. Shut off the controller power switch.

2. See Figure 17. Unscrew and separate theretaining nut (9) and nozzle (8) assembly fromthe spray gun.

3. Pull the tubing adapter (7) from the powdertube.

6

5

Figure 18 Remove the Lock Knob and Powder Tubing

4. See Figure 18. Unscrew the locking knob (5)on the gun adapter (6).

5. Pull the powder tube out through the gunadapter.

6. Replace the powder tube by following steps 4−8of the Installation procedure on page 7.

7. Screw the new nozzle back into the retainingnut, then install the nozzle onto the spray gun.

Control Cable Replacement 1. Shut off the gun controller power switch and

remove the powder tubing from the gun. Referto Nozzle and Powder Tubing Replacement.

2. Remove the spray gun from the spray area (atleast one meter (3 ft) from the spray booth).

3. See Figure 19. Remove the screw (31)securing the cable (32) to the bottom of the gunhandle.

4. Rotate the cable to release it from the handlebase. Gently pull down on the cable until youcan grasp the trigger switch receptacle (23).

5. Disconnect the trigger cable plug (J3) from thetrigger switch receptacle.

23

32

31

J3

Figure 19 Disconnecting the Control Cable from theHandle



Control Cable Replacement (contd)

6. See Figure 20. Remove the end capscrew (17) and end cap (16) from the gun body.

16

17

Figure 20 Removing the End Cap

7. See Figure 21. Disconnect the multiplierconnector (J2) from the multiplier receptacle.

8. Remove the post and lock washer (13, 12) todisconnect the ground terminal (GND).

J2

GND

1312

Figure 21 Disconnecting the Control Cable

9. See Figure 22. Lift up on the back of the gunbody (11) to unsnap it from the handle, thenpush the body forward to separate it from thehandle (19).

11

Feed cablethrough here

19

Figure 22 Separating the Gun Body from the Handle

10. Feed the ground and multiplier wiring throughthe opening in the handle.

11. Perform the previous steps in reverse to installa new cable.



Resistor Replacement

Resistor Removal 1. See Figure 17. Unscrew the nozzle (8) and

retaining nut (9) from the spray gun.

2. Pull the tubing adapter (7) out of the powdertubing.

3. See Figure 23. Unscrew the lock knob (5) andpull the powder tubing out of the gunadapter (6).

4. Loosen the set screw (3) in the bottom on thegun adapter.

6

53

Figure 23 Loosening the Adapter Set Screw

5. See Figure 24. Pull the gun adapter (6) straightoff the gun body (11).

11

6

Figure 24 Removing the Adapter

6. See Figure 25. Unscrew the resistor holder (1)from the multiplier (15).

15

1

Figure 25 Removing the Resistor Holder

7. See Figure 26. Remove the contactspacer (14) from the multiplier well. Wipe thedielectric grease off the contact spacer.

Multiplier Well

14

Figure 26 Removing the Contact Spacer

8. See Figure 27. Remove the resistor (2) fromthe resistor holder (1).

9. Clean and inspect the resistor holder. Replacethe holder if you find carbon tracks or pin holes.

2 1Resistor Well

Figure 27 Removing the Resistor from the Holder

Resistor Installation 1. See Figure 27. Inject approximately 0.60 cc of

dielectric grease into the resistor well.

2. Insert the resistor into the resistor holder until itbottoms out, then fill the resistor well withapproximately 0.8 cc of dielectric grease.

3. See Figure 26. Insert the contact spacer intothe multiplier well. Fill the multiplier well withdielectric grease.

4. See Figure 25. Screw the resistor holder ontothe multiplier.

5. See Figures 24 and 23. Install the adapter onthe gun body. Tighten the set screw.

6. See Figure 17. Follow the Tubing Installationprocedure on page 7 to install the powdertubing.

7. Replace the nozzle and retaining nut on thespray gun.



Multiplier Replacement

Removal 1. Remove the resistor holder. Refer to steps 1−6

of the Resistor Replacement procedure.

2. Remove the end cap and disconnect the controlcable. Refer to steps 6−8 of the Control CableReplacement procedure.

3. Push the multiplier out of the gun body from thefront.

4. See Figure 28. Remove the contactspacer (14) from the multiplier well. Clean thedielectric grease off the contact spacer.

14

Figure 28 Removing the Contact Spacer

Assembly 1. See Figure 28. Insert the contact spacer into

the multiplier well. Fill the multiplier well withdielectric grease.

2. Install the multiplier into the gun body.

3. Fill the resistor holder well with dielectricgrease. Refer to Resistor Installationinstructions.

4. See Figure 25. Screw the resistor holder ontothe multiplier.

5. See Figures 24 and 23. Install the adapter overthe electrode and resistor holders. Tighten theset screw.

6. See Figure 21. Connect the ground wire to thegun body with the lockwasher and post.Connect the multiplier connector (J3) to themultiplier receptacle.

7. See Figure 20. Install the end cap on the gunbody with the screw.

8. See Figure 17. Follow the Tubing Installationprocedure on page 7 to install the powdertubing.

9. Replace the nozzle and retaining nut on thespray gun.



Parts

Spray Gun Parts List

Item Part Description Quantity Note— 1077058 GUN, manual, 95 kV, generation II, Prodigy 1 D1 1077264 � HOLDER, resistor, Prodigy, manual, generation 2 12 1053912 � KIT, resistor, cable, series 13 982455 � SCREW, set, M6 x 1 x 8, nylon, black 15 1047934 � KNOB, lock, powder tube 14 940117 � O-RING, silicone, 0.312 x 0.438 x 0.063 in. 36 1077421 � KIT, adapter/spring plunger assembly, generation II 17 1093440 � ADAPTER, tubing, gun , Prodigy 18 1062223 � KIT, nozzle, 70 degree, conical 1 A, E9 1078850 � NUT, retaining 110 940212 � O-RING, silicone, 0.938 x 1.063 x 0.063 in. 111 1074027 � BODY, manual gun, Prodigy 112 983416 � WASHER, lock, internal, M4, steel, zinc 113 288553 � POST, spacer, hex 114 1053595 � SPACER, contact 115 288552 � POWER SUPPLY, 95 kV, negative 1 B16 333988 � KIT, end cap, manual gun 117 982800 � SCREW, pan, recessed, M4 x 6, black, zinc 118 1069680 � GASKET, cover, manual gun 119 288561 � HANDLE, w/cover, manual gun 1

19A 288534 � � GASKET, base, manual gun 120 288541 � TRIGGER, purge, manual gun 121 1093489 � TRIGGER, actuator, manual gun 122 288537 � PIVOT, threaded, gun, M5 123 288549 � SWITCH, keypad, trigger/purge 124 288550 � PAD, ground, small, manual gun 1 B25 288538 � BASE, handle, manual gun 126 1077437 � GROMMET, Buna-N, 1/2-in. ID x 1.00 in. OD x 9/32 127 288545 � BRACKET, hose, manual gun 128 982801 � SCREW, oval, recessed, M4 x 20, black, zinc 229 328524 � CONNECTOR, male, w/integral hex, 6 mm tube x M5 130 973402 � PLUG, pipe, socket, flush, 1/8 in. NPT, zinc 131 982825 � SCREW, pan head, rec, M4 x 12, with integral lock washer

bezel, black, zinc1

32 1080539 � KIT, cable, manual gun, Prodigy, 6 meter 1 BNS 1073706 � KIT, nozzle, flat spray, dual slot, converging angle, 1 mm 1 A, ENS 1093531 � SLEEVING, mesh, tube insertion tool 1 C

NOTE A: Refer to page 23 for conical nozzles and components; pages 24 and 25 for flat spray, cross, and pinpointnozzles and components.

B: Refer to page 21 for options.

C: Use this tool to install flexible powder tubing through the lock knob.

D: Part is obsolete.

E: Not included in repair kit PN 1611771.

NS: Not Shown



Spray Gun Exploded View

11

10

1918

17

15

14

13 12

16

26

20

21

23

22

24

25

2728

30

29

2831

32

19A

1

2

3

4

5

67

8

9

4

Figure 29 Prodigy Manual Spray Gun Exploded Parts Illustration



Service Kits Part Description Note

1080539 KIT, cable, manual gun, Prodigy, 6 meter

1053912 KIT, resistor, cable, series

1077424 KIT, resistor holder, Prodigy, generation II

Spray Gun Body Repair KitPart Description Note

1611771 KIT, repair, gun body, Prodigy, manual A

NOTE A: Refer to parts list for bill of materials.

Options Part Description Note

1073682 KIT, tool, insertion/extraction, nozzle

288544 PAD, ground, medium, manual gun A

302112 POWER SUPPLY, 95 kV, positive

245733 APPLICATOR, dielectric grease B

161411 PLUG, shorting, IPS C

1073027 CABLE, manual gun, 4 meter extension D

1603177 LANCE EXTENSION, 150 mm, Prodigy, generation II E

1603178 LANCE EXTENSION, 300 mm, Prodigy, generation II E

NOTE A: For operators with larger hands. Replaces standard pad.

B: Carton of 12 3-cc dielectric grease applicators.

C: Use for testing multiplier/resistor/electrode resistance.

D: Do not add more than two extension cables to the gun cable.

E: Instruction sheet 1603191, shipped with lance extensions, contains spare parts list for extensions.

Shorting Plug Nozzle Tool

Figure 30 Options



Powder and Air Tubing Powder and air tubing are not supplied with the spray gun.

Part Description Note1613849 TUBING, powder, 8 mm x 6 mm, 40 m1613850 TUBING, powder, 8 mm x 6 mm, 160 m1615026 TUBING, powder, 8 mm x 6 mm, clear, 60 ft A1606695 TUBING, powder, 8 mm x 6 mm, clear, 500 ft A

900742 TUBING, polyurethane, 6/4 mm, blue (Air)

1062178 TUBING CUTTER, 12 mm or less1078006 ADAPTER, tube, barb, powder, Prodigy pump, generation II

NOTE A: Optional tubing for use with HDLV pumps.



Conical Nozzles Part Description Effective

Pattern SizeUsage Note

1062223 KIT, nozzle, 70 degree, conical 4−6 inches(101−152 mm)

General use onmanual orautomatic guns

A

1062160 � NOZZLE, 70 degree, conical (shell) C

1062166 KIT, nozzle, 100 degree, conical 6−8 inches(152−230 mm)


B


1073819 KIT, nozzle, conical, 40 degree, conical 2−4 inches(51−102 mm)

Manual coatingand touch-up

B


NOTE A: One of each supplied with spray gun.

B: Optional nozzles, not included with spray gun.

C: Nozzle shell only. Does not include internal components.

40 Degree 70 Degree 100 Degree

Figure 31 Conical Nozzles

Conical Nozzle Components Refer to Options on page 21 for nozzle tool used to disassemble nozzles.

Item Part Description Quantity Note1 940203 O-RING, silicone, 0.875 x 1.00 x 0.063 in. 1

2 1047537 ELECTRODE ring 1

3 940126 O-RING, silicone, 0.375 x 0.50 x 0.063 in. 1

4 940163 O-RING, silicone, 0.625 x 0.75 x 0.063 in. 1

5 1073625 INSERT, metric, conical/flat nozzles 1

6 1073624 CONE, porous, nozzle 1 A

7 1062177 ELECTRODE, spring contact, 0.094 dia, Prodigy 1

NOTE A: Also available in quantities of 10. Order kit 1073707.

12

34

56

7

NOZZLE SHELLRefer to Conical Nozzle List for replacementpart number

Figure 32 Conical Nozzle Components



Flat Spray, Cross, and Pinpoint Nozzles Refer to Figure 34 and parts list for nozzle internal components.

Part Description EffectivePattern Size

Usage Note

1073706 KIT, nozzle, flat spray, dual slot, convergingangle, 1 mm

8−10 inches(203−254 mm)


1073726 � KIT, nozzle, dual converging slots, shell withelectrode

C

1077385 KIT, nozzle, flat spray, Prodigy, 75 degree 6−8 inches(152−230 mm)


A

1077395 � NOZZLE, shell with electrode, flat spray,Prodigy, 75 degrees

C



A

1077394 � NOZZLE, shell with electrode, flat spray,Prodigy, 90 degree

C



A


C


Large flatsurfaces

A


C


Large flatsurfaces

A


C

1077584 NOZZLE assembly, cross, Prodigy, 4 slot, 60degree

3−5 inches(76−127 mm)


B

1077893 � NOZZLE, shell with electrode, cross,Prodigy, 4 slot, 60 degree

C


2−4 inches(51−102 mm)


B


C


2−3 inches(51−76 mm)

Manual coating −deep recesses

B


C

1077587 NOZZLE assembly, pinpoint, Prodigy, 10 hole Pinpoint Manual coating −touch-up anddeep recesses

B

1077896 � NOZZLE, shell with electrode, pinpoint,Prodigy, 10 hole

C

NOTE A: These kits include spare nozzle shell with electrode.

B: Complete nozzle assembly with shell.

C: Nozzle shell with electrode only.



Flat Spray, Cross, and Pinpoint Nozzles (contd)

Dual Slot Single Slot Nozzles

Cross NozzlesFlat Spray Nozzles

4 Slot 60 Degree 4 Slot 90 Degree 6 Slot 60 Degree

Pinpoint Nozzle

Figure 33 Flat Spray, Cross, and Pinpoint Nozzles

Flat Spray, Cross, and Pinpoint Nozzle Components

Refer to Options on page 21 for nozzle tool used to disassemble nozzles.

Item Part Description Quantity Note− — � NOZZLE ASSEMBLIES 1 A

1 940203 � O-RING, silicone, 0.875 x 1.00 x 0.063 in. 1

2 1047537 � ELECTRODE ring 1



5 1073625 � INSERT, metric, conical/flat nozzles 1

6 1073624 � CONE, porous, nozzle 1 B7 — � NOZZLE shell with electrode 1 A

NOTE A: Refer to Nozzle parts list on previous page for part numbers.

B: Also available in quantities of 10. Order kit 1073707.

1

23

4

5

6

7

Figure 34 Flat Spray, Cross, and Pinpoint Nozzle Components



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Prodigy Generation II Manual Powder Spray Gunemanuals.nordson.com/finishing/files/Powder/1077434.pdf · Prodigy Generation II Manual Powder Spray Gun 3 2019 Nordson Corporation Part